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Proposed Rule

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Airworthiness Directives; Engine Components, Inc. (ECi) Reciprocating Engine Cylinder Assemblies

A Proposed Rule by the Federal Aviation Administration on 07/30/2009

Published Document: E9-18118 (74 FR 37955)

This document has been published in the Federal Register. Use the PDF linked in the document sidebar for the official electronic format.

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Department of Transportation
Federal Aviation Administration
  1. 14 CFR Part 39
  2. [Docket No. FAA-2008-0052; Directorate Identifier 2008-NE-01-AD]
  3. RIN 2120-AA64

AGENCY:

Federal Aviation Administration (FAA), DOT.

ACTION:

Notice of proposed rulemaking (NPRM).

SUMMARY:

The FAA proposes to supersede an existing airworthiness directive (AD) for Lycoming Engines (formerly Textron Lycoming) models 320, 360, and 540 series, “Parallel Valve” reciprocating engines, with certain Engine Components, Inc. (ECi) cylinder assemblies, part number (P/N) AEL65102 series “Titan,” installed. That AD currently requires initial and repetitive visual inspections and compression tests to detect cracks at the head-to-barrel interface, replacement of cylinder assemblies found cracked, and replacement of certain cylinder assemblies at new, reduced times-in-service. This proposed AD would require the same actions, but for an expanded population of cylinder assemblies. This proposed AD results from reports of 10 additional cylinder head separations since issuing AD 2008-19-05, on cylinder serial numbers not listed in that AD. We are proposing this AD to prevent loss of engine power due to cracks at the head-to-barrel interface and possible engine failure caused by separation of a cylinder head, which could result in loss of control of the aircraft.

DATES:

We must receive any comments on this proposed AD by September 28, 2009.

ADDRESSES:

Use one of the following addresses to comment on this proposed AD:

  • Federal eRulemaking Portal: Go to http://www.regulations.gov and follow the instructions for sending your comments electronically.
  • Mail: Docket Management Facility, U.S. Department of Transportation, 1200 New Jersey Avenue, SE., West Building Ground Floor, Room W12-140, Washington, DC 20590-0001.
  • Hand Delivery: Deliver to Mail address above between 9 a.m. and 5 p.m., Monday through Friday, except Federal holidays.
  • Fax: (202) 493-2251.

FOR FURTHER INFORMATION CONTACT:

Peter W. Hakala, Aerospace Engineer, Special Certification Office, FAA, Rotorcraft Directorate, 2601 Meacham Blvd., Fort Worth, TX 76193; e-mail: ; telephone (817) 222-5145; fax (817) 222-5785.

SUPPLEMENTARY INFORMATION:

Comments Invited

We invite you to send any written relevant data, views, or arguments regarding this proposal. Send your comments to an address listed under ADDRESSES . Include “Docket No. FAA-2008-0052; Directorate Identifier 2008-NE-01-AD” in the subject line of your comments. We specifically invite comments on the overall regulatory, economic, environmental, and energy aspects of the proposed AD. We will consider all comments received by the closing date and may amend the proposed AD in light of those comments.

We will post all comments we receive, without change, to http://www.regulations.gov, including any personal information you provide. We will also post a report summarizing each substantive verbal contact with FAA personnel concerning this proposed AD. Using the search function of the Web site, anyone can find and read the comments in any of our dockets, including, if provided, the name of the individual who sent the comment (or signed the comment on behalf of an association, business, labor union, etc.). You may review the DOT's complete Privacy Act Statement in the Federal Register published on April 11, 2000 (65 FR 19477-78).

Examining the AD Docket

You may examine the AD docket on the Internet at http://www.regulations.gov; or in person at the Docket Operations office between 9 a.m. and 5 p.m., Monday through Friday, except Federal holidays. The AD docket contains this proposed AD, the regulatory evaluation, any comments received, and other information. The street address for the Docket Operations office (telephone (800) 647-5527) is the same as the Mail address provided in the ADDRESSES section. Comments will be available in the AD docket shortly after receipt.

Discussion

The FAA proposes to amend 14 CFR part 39 by superseding AD 2008-19-05, Amendment 39-15672 (73 FR 53105, September 15, 2008). That AD requires initial and repetitive visual inspections and compression tests to detect cracks at the head-to-barrel interface, replacement of cylinder assemblies found cracked, and replacement of certain cylinder assemblies, at new reduced times-in-service. That AD was the result of reports of 45 failures with head separations of ECi cylinder assemblies. That condition, if not corrected, could result in loss of engine power due to cracks at the head-to-barrel interface in the cylinder assemblies and possible engine failure caused by separation of a cylinder head, which could result in loss of control of the aircraft.

Actions Since AD 2008-19-05 Was Issued

Since AD 2008-19-05 was issued, we received reports of 10 additional cylinder head separations, on cylinder serial numbers not listed in that AD. To date, there have been a total of 55 head separations resulting in engine shutdowns and emergency landings in airplanes and helicopters.

FAA's Determination and Requirements of the Proposed AD

We have evaluated all pertinent information and identified an unsafe condition that is likely to exist or develop on other products of this same type design. For that reason, we are proposing this AD, which would require initial and repetitive visual inspections and compression tests to detect cracks at the head-to-barrel interface, replacement of cylinder assemblies found cracked, and replacement of certain cylinder assemblies, at new reduced times-in-service. The proposed AD would require: ( printed page 37956)

  • Determining if Group “A” or Group “B” ECi cylinder assemblies, P/N AEL65102 series “Titan,” with cylinder head P/N AEL85099, are installed on your engine.
  • For any Group “A” cylinder assembly, performing initial and repetitive visual inspections and compression tests, and replacement not later than 2,000 operating hours time-in-service (TIS) or within 25 operating hours TIS if the cylinder assembly exceeds 2,000 operating hours TIS on the effective date of the proposed AD.
  • For any Group “A” cylinder assembly installed in a helicopter, performing the same initial and repetitive visual inspections and compression tests, but replacement not later than 1,500 operating hours TIS or within 25 operating hours TIS if the cylinder assembly exceeds 1,500 operating hours TIS on the effective date of the proposed AD.
  • Expanding the serial numbers affected of Group “B” cylinder assemblies, and performing the same initial visual inspection and compression test, and replacement not later than 350 operating hours TIS or within 25 operating hours TIS if the cylinder assembly exceeds 350 operating hours TIS on the effective date of the proposed AD.

Costs of Compliance

We estimate that this proposed AD would affect 18,000 ECi cylinder assemblies installed in aircraft of U.S. registry. The visual inspection and compression tests would take about 4 work-hours for each engine. An individual cylinder replacement would require $1,100 for parts and 6 work-hours. Lycoming engines with a set of 4 ECi cylinders would require 12 work-hours for the cylinder replacement. Lycoming engines with a set of 6 ECi cylinders would require 16 work-hours for the cylinder replacement. We estimate 18 percent of the affected population of cylinders would be replaced. We estimate the total cost of the AD to U.S. operators to be $10,172,000. Our estimate is exclusive of any possible warranty coverage.

Authority for This Rulemaking

Title 49 of the United States Code specifies the FAA's authority to issue rules on aviation safety. Subtitle I, Section 106, describes the authority of the FAA Administrator. Subtitle VII, Aviation Programs, describes in more detail the scope of the Agency's authority.

We are issuing this rulemaking under the authority described in Subtitle VII, Part A, Subpart III, Section 44701, “General requirements.” Under that section, Congress charges the FAA with promoting safe flight of civil aircraft in air commerce by prescribing regulations for practices, methods, and procedures the Administrator finds necessary for safety in air commerce. This regulation is within the scope of that authority because it addresses an unsafe condition that is likely to exist or develop on products identified in this rulemaking action.

Regulatory Findings

We have determined that this proposed AD would not have federalism implications under Executive Order 13132. This proposed AD would not have a substantial direct effect on the States, on the relationship between the national Government and the States, or on the distribution of power and responsibilities among the various levels of government.

For the reasons discussed above, I certify that the proposed AD:

1. Is not a “significant regulatory action” under Executive Order 12866;

2. Is not a “significant rule” under the DOT Regulatory Policies and Procedures (44 FR 11034, February 26, 1979); and

3. Would not have a significant economic impact, positive or negative, on a substantial number of small entities under the criteria of the Regulatory Flexibility Act.

We prepared a regulatory evaluation of the estimated costs to comply with this proposed AD. See the ADDRESSES section for a location to examine the regulatory evaluation.

List of Subjects in 14 CFR Part 39

  • Air transportation
  • Aircraft
  • Aviation safety
  • Safety

The Proposed Amendment

Under the authority delegated to me by the Administrator, the Federal Aviation Administration proposes to amend 14 CFR part 39 as follows:

PART 39—AIRWORTHINESS DIRECTIVES

1. The authority citation for part 39 continues to read as follows:

Authority: 49 U.S.C. 106(g), 40113, 44701.

[Amended]

2. The FAA amends § 39.13 by removing Amendment 39-15672 (73 FR 53105, September 15, 2008) and by adding a new airworthiness directive to read as follows:

Engine Components, Inc. (ECi): Docket No. FAA-2008-0052; Directorate Identifier 2008-NE-01-AD.

Comments Due Date

(a) The Federal Aviation Administration (FAA) must receive comments on this airworthiness directive (AD) action by September 28, 2009.

Affected ADs

(b) This AD supersedes AD 2008-19-05, Amendment 39-15672.

Applicability

(c) If your engine has not been overhauled, or not had any cylinder assemblies replaced since new, no further action is required.

(d) This AD applies to the Lycoming Engines (formerly Textron Lycoming) models 320, 360, and 540 series, “Parallel Valve,” reciprocating engines listed in Table 1 of this AD, with ECi cylinder assembly, part number (P/N) AEL65102 series “Titan,” and with cylinder head, P/N AEL85099, installed.

(1) The applicable cylinder assembly serial numbers (SNs) are SN 1138-02 through SN 35171-22, (referred to in this AD as Group “A” cylinder assemblies); and

(2) SN 35239-01 through SN 42179-30 (referred to in this AD as Group “B” cylinder assemblies).

(3) The cylinder assembly P/N is at the crankcase end of the cylinder assembly, and might be difficult to see. As a guide in determining if your cylinder assemblies are affected, all affected cylinder assemblies have cylinder head P/N AEL85099. The cylinder head P/N is at the top of the cylinder head, near the intake and exhaust valve springs, and is easier to locate than the cylinder assembly P/N.

(4) The set of numbers appearing on the cylinder, above and to the left of the SN, in the form of “123456” is not used for determining applicability.

Table 1—Engine Models
Cylinder assembly part number Installed on engine models
AEL65102-NST04 O-320-A1B, A2B, A2C, A2D, A3A, A3B, B2B, B2C, B2D, B2E, B3B, B3C, C2B, C2C, C3B, C3C, D1A, D1AD, D1B, D1C, D1D, D1F, D2A, D2B, D2C, D2F, D2G, D2H, D2J, D3G, E1A, E1B, E1C, E1F, E1J, E2A, E2B, E2C, E2D, E2E, E2F, E2G, E2H, E3D, E3H.
  IO-320-A1A, A2A, B1A, B1B, B1C, B1D, B1E, B2A, D1A, D1AD, D1B, D1C, E1A, E1B, E2A, E2B.
  AEIO-320-D1B, D2B, E1A, E1B, E2A, E2B.
( printed page 37957)
  AIO-320-A1A, A1B, A2A, A2B, B1B, C1B.
  LIO-320-B1A.
AEL65102-NST05 IO-320-C1A, C1B, C1F, F1A.
  LIO-320-C1A.
AEL65102-NST06 O-320-A1A, A2A, A2B, A2C, A3A, A3B, A3C, E1A, E1B, E2A, E2C, (also, an O-320 model with no suffix).
  IO-320-A1A, A2A.
AEL65102-NST07 IO-320-B1A, B1B.
  LIO-320-B1A.
AEL65102-NST08 O-320-B1A, B1B, B2A, B2B, B3A, B3B, B3C, C1A, C1B, C2A, C2B, C3A, C3B, C3C, D1A, D1B, D2A, D2B, D2C.
AEL65102-NST10 O-360-A1A, A1C, A1D, A2A, A2E, A3A, A3D, A4A, B1A, B1B, B2A, B2B, C1A, C1C, C1G, C2A, C2B, C2C, C2D, D1A, D2A, D2B.
  IO-360-B1A, B1B, B1C.
  HO-360-A1A, B1A, B1B.
  HIO-360-B1A, B1B.
  AEIO-360-B1B.
  O-540-A1A, A1A5, A1B5, A1C5, A1D, A1D5, A2B, A3D5, A4A5, A4B5, A4C5, A4D5, B1A5, B1B5, B1D5, B2A5, B2B5, B2C5, B4A5, B4B5, D1A5, E1A, E4A5, E4B5, E4C5, F1A5, F1B5, G1A5, G2A5.
  IO-540-C1B5, C1C5, C2C, C4B5, C4B5D, C4C5, D4A5, D4B5, N1A5.
AEL65102-NST12 O-360-A1A, A1AD, A1D, A1F, A1F6, A1F6D, A1G, A1G6, A1G6D, A1H, A1H6, A1J, A1LD, A1P, A2A, A2D, A2F, A2G, A2H, A3A, A3AD, A3D, A4A, A4AD, A4D, A4G, A4J, A4JD, A4K, A4M, A4N, A4P, A5AD, B1A, B2C, C1A, C1C, C1E, C1F, C1G, C2A, C2B, C2C, C2D, C2E, C4F, C4P, D2A, F1A6, G1A6.
  HO-360-C1A.
  LO-360-A1G6D, A1H6.
  HIO-360-B1A, B1B, G1A.
  LTO-360-A1A6D.
  TO-360-A1A6D.
  IO-360-B1B, B1BD, B1D, B1E, B1F, B1F6, B1G6, B2E, B2F, B2F6, B4A, E1A, L2A, M1A, M1B.
  AEIO-360-B1B, B1D, B1E, B1F, B1F6, B1G6, B1H, B2F, B2F6, B4A, H1A, H1B.
  O-540-A4D5, B2B5, B2C5, B2C5D, B4B5, B4B5D, E4A5, E4B5, E4C5, G1A5, G2A5, H1A5, H1A5D, H1B5, H1B5D, H2A5, H2A5D, H2B5D.
  IO-540-C4B5, C4B5D, C4D5, C4D5D, D4A5, D4B5, D4C5, N1A5, N1A5D, T4A5D, T4B5, T4B5D, T4C5D, V4A5, V4A5D.
  AEIO-540-D4A5, D4B5, D4C5, D4D5.
AEL65102-NST26 IO-540-J4A5, R1A5.
  TIO-540-C1A, E1A, G1A, H1A.
AEL65102-NST38 IO-360-F1A.
  TIO-540-AA1AD, AB1AD, AB1BD, AF1A, AG1A, AK1A, C1A, C1AD, K1AD.
  LTIO-540-K1AD.
AEL65102-NST43 O-360-J2A.
  O-540-F1B5, J1A5D, J1B5D, J1C5D, J1D5D, J2A5D, J2B5D, J2C5D, J2D5D, J3A5, J3A5D, J3C5D.
  IO-540-AB1A5, W1A5, W1A5D, W3A5D.
AEL65102-NST44 O-540-L3C5D.

The Lycoming Engines (formerly Textron Lycoming) models 320, 360, and 540 series, “Parallel Valve”, reciprocating engines are installed on, but not limited to, the aircraft listed in the following Table 2:

Table 2—Engines Installed On, But Not Limited To
Engine models Installed on, but not limited to
O-320-A1A Piper Aircraft: Tri-Pacer (PA-22 “150”, PA-22S “150”), Apache (PA-23), Pawnee (PA-25).
  Doyn Aircraft: Doyn-Cessna (170, 170A, 170B).
  Mooney Aircraft: Mark (20A).
  Dinfia: Ranquel (1A-46).
  Simmering-Graz Pauker: Flamingo (SGP-M-222).
  Aviamilano: Scricciolo (P-19).
  Vos Helicopter Co.: Spring Bok.
O-320-A1B Piper Aircraft: Tri-Pacer (PA-22 “150”, PA-22S “150”), Apache (PA-23).
  Doyn Aircraft: Doyn-Cessna (170, 170A, 170B).
  S.O.C.A.T.A.: Horizon (Gardan).
O-320-A2A Piper Aircraft: Tri-Pacer (PA-22 “150”, PA-22S “150”), Agriculture (PA-18A “150”), Super Cub (PA-18 “150”), Caribbean (PA-22 “150”), Pawnee (PA-25).
  Intermountain Mfg. Co.: Call Air Texas (A-5, A-5T).
  Lake Aircraft: Colonial (C-1).
  Rawdon Bros.: Rawdon (T-1, T-15, T-15D).
  Shinn Engineering: Shinn (2150-A).
( printed page 37958)
  Dinfia: Ranquel (1A-46).
  Neiva: (1PD-5802).
  Sud: Gardan-Horizon (GY-80).
  LaVerda: Falco (F8L Series II, America).
  Malmo: Vipan (MF1-10).
  Kingsford Smith: Autocrat (SCRM-153).
  Aero Commander: 100.
O-320-A2B Piper Aircraft: Tri-Pacer (PA-22 “150”, PA-22S “150”), Cherokee (PA-28 “150”), Super Cub (PA-18 “150”).
  Champion Aircraft: Challenger (7GCA, 7GCB, 7KC), Citabria (7GCAA, 7GCRC), Agriculture (7GCBA).
  Beagle: Pup (150).
  Artic: Interstate S1B2.
  Robinson: R-22.
  Varga: Kachina 2150A.
O-320-A2C Robinson: R-22.
  Cicare: Cicare AG.
  Bellanca Aircraft: Citabria 150 (7GCAA), Citabria 150S (7GCBC).
O-320-A2D Piper Aircraft: Apache (PA-23).
O-320-A3A Doyn Aircraft: Doyn-Cessna (170, 170A, 170B).
  Corben-Fettes: Globe Special (Globe GC-1B).
O-320-A3B Piper Aircraft: Apache (PA-23).
  Doyn Aircraft: Doyn-Cessna (170, 170A, 170B).
  Teal II: TSC (1A2).
O-320-B1A Piper Aircraft: Apache (PA-23 “160”).
  Doyn Aircraft: Doyn-Cessna (170, 170A, 170B).
  Malmo: Vipan (MF1-10).
O-320-B1B Piper Aircraft: Apache (PA-23 “160”).
  Doyn Aircraft: Doyn-Cessna (170, 170A, 170B).
O-320-B2A Piper Aircraft: Tri-Pacer (PA-22 “160”, PA-22S “160”).
O-320-B2B Piper Aircraft: Tri-Pacer (PA-22 “160”, PA-22S “160”).
  Beagle: Airedale (D5-160).
  Fuji-Heavy Industries: Fuji (F-200).
  Uirapuru: Aerotec 122.
O-320-B2C Robinson: R-22.
O-320-B2D Maule: MX-7-160.
O-320-B2E Lycon.
O-320-B3A Piper Aircraft: Apache (PA-23 “160”).
  Doyn Aircraft: Doyn-Cessna (170, 170A, 170B).
O-320-B3B Piper Aircraft: Apache (PA-23 “160”).
  Doyn Aircraft: Doyn-Cessna (170, 170A, 170B).
  Sud: Gardan (GY80-160).
O-320-C1A Piper Aircraft: Apache (PA-23 “160”).
  Riley Aircraft: Rayjay (Apache).
O-320-C1B Piper Aircraft: Apache (PA-23 “160”).
O-320-C3A Piper Aircraft: Apache (PA-23 “160”).
O-320-C3B Piper Aircraft: Apache (PA-23 “160”).
O-320-D1A Sud: Gardan (GY-80).
  Gyroflug: Speed Cancard.
  Grob: G115.
O-320-D1F Slingsby: T67 Firefly.
O-320-D2A Piper Aircraft: Cherokee (PA-28S “160”).
  Robin: Major (DR400-140B), Chevalier (DR-360), (R-3140).
  S.O.C.A.T.A.: Tampico TB9.
  Slingsby: T67C Firefly.
  Daetwyler: MD-3-160.
  Nash Aircraft Ltd.: Petrel.
  Aviolight: P66D Delta.
  General Avia: Pinguino.
O-320-D2B Beech Aircraft: Musketeer (M-23).
  Piper Aircraft: Cherokee (PA-28 “160”).
O-320-D2J Cessna Aircraft: Skyhawk 172.
O-320-D3G Piper Aircraft: Warrior II, Cadet (PA-28-161).
O-320-E1A Grob: G115.
O-320-E1C M.B.B. (Messerschmitt-Boelkow-Blohm): Monsun (BO-209-B).
O-320-E1F M.B.B.: Monsun (BO-209-B).
O-320-E2A Piper Aircraft: Cherokee (PA-28 “140”, PA-28 “150”).
  Robin: Major (DR-340), Sitar, Bagheera (GY-100-135).
  S.O.C.A.T.A.: Super Rallye (MS-886), Rallye Commodore (MS-892).
  Siai-Marchetti: (S-202).
  F.F.A.: Bravo (AS-202/15).
  Partenavia: Oscar (P66B), Bucker (131 APM).
  Aeromot: Paulistina P-56.
( printed page 37959)
  Pezetel: Koliber 150.
O-320-E2C Beech Aircraft: Musketeer III (M-23III).
  M.B.B.: Monsun (BO-209-B).
O-320-E2D Cessna Aircraft: Cardinal (172-I, 177).
O-320-E2F M.B.B.: Monsun (BO-209-B), Wassmer Pacific (WA-51).
O-320-E2G American Aviation Corp.: Traveler.
O-320-E3D Piper Aircraft: Cherokee (140).
  Beech Aircraft: Sport.
IO-320-B2A Piper Aircraft: Twin Comanche (PA-30).
IO-320-B1C Hi. Shear: Wing.
IO-320-B1D Ted Smith Aircraft: Aerostar.
IO-320-C1A Piper Aircraft: Twin Comanche (PA-30 Turbo).
IO-320-D1A M.B.B.: Monsun (BO-209-C).
IO-320-D1B M.B.B.: Monsun (BO-209-C).
IO-320-E1A M.B.B.: Monsun (BO-209-C).
IO-320-E1B Bellanca Aircraft.
IO-320-E2A Champion Aircraft: Citabria.
IO-320-E2B Bellanca Aircraft.
IO-320-F1A CAAR Engineering: Carr Midget.
LIO-320-B1A Piper Aircraft: Twin Comanche (PA-39).
LIO-320-C1A Piper Aircraft: Twin Comanche (PA-39).
AIO-320-B1B M.B.B.: Monsun (BO-209-C).
AEIO-320-D1B Slingsby: T67M Firefly.
AEIO-320-D2B Hundustan Aeronautics Ltd.: HT-2.
AEIO-320-E1A Bellanca Aircraft.
  Champion Aircraft.
AEIO-320-E1B Bellanca Aircraft.
  Champion Aircraft: Decathalon (8KCAB-CS).
AEIO-320-E2B Bellanca Aircraft.
  Champion Aircraft: Decathalon (8KCAB).
O-320-A1A Riley Aircraft: Riley Twin.
O-360-A1A Beech Aircraft: Travel Air (95, B-95).
  Piper Aircraft: Comanche (PA-24).
  Intermountain Mfg. Co.: Call Air (A-6).
  Lake Aircraft: Colonial (C-2, LA-4, 4A or 4P).
  Doyn Aircraft: Doyn-Cessna (170B, 172, 172A, 172B).
  Mooney Aircraft: Mark “20B” (M-20B).
  Earl Horton: Pawnee (Piper PA-25).
  Dinfia: Ranquel (1A-51).
  Neiva: (1PD-5901).
  Regente: (N-591).
  Wassmer: Super 4 (WA-50A), Sancy (WA-40), Baladou (WA-40), Pariou (WA-40).
  Sud: Gardan (GY-180).
  Boelkow: (207).
  Partenavia: Oscar (P-66).
  Siai-Marchetti: (S-205).
  Procaer: Picchio (F-15-A).
  S.A.A.B.: Safir (91-D).
  Malmo: Vipan (MF-10B).
  Aero Boero: AB-180.
  Beagle: Airedale (A-109).
  DeHavilland: Drover (DHA-3MK3).
  Kingsford-Smith: Bushmaster (J5-6).
  Aero Engine Service Ltd.: Victa (R-2).
O-360-A1AD S.O.C.A.T.A.: Tabago TB-10.
O-360-A1D Piper Aircraft: Comanche (PA-24).
  Lake Aircraft: Colonial (LA-4, 4A or 4P).
  Doyn Aircraft: Doyn-Beech (Beech 95).
  Mooney Aircraft: Master “21” (M-20E), Mark “20B”, “20D”, (M20B, M20C), Mooney Statesman (M-20G).
  Dinfia: Querandi (1A-45).
  Wassmer: (WA-50).
  Malmo: Vipan (MF1-10).
  Cessna Aircraft: Skyhawk.
  Doyn Aircraft: Doyn-Piper (PA-23 “160”).
O-360-A1F6 Cessna Aircraft: Cardinal.
O-360-A1F6D Cessna Aircraft: Cardinal 177.
  Teal III: TSC (1A3).
O-360-A1G6 Aero Commander.
O-360-A1G6D Beech Aircraft: Duchess 76.
O-360-A1H6 Piper Aircraft: Seminole (PA-44).
O-360-A1LD Wassmer: Europa WA-52.
O-360-A1P Aviat: Husky.
( printed page 37960)
O-360-A2A Center Est Aeronautique: Regente (DR-253).
  S.O.C.A.T.A.: Rallye Commodore (MS-893).
  Societe Aeronautique Normande: Mousquetaire (D-140).
  Boelkow: Klemm (K1-107C).
  Partenavia: Oscar (P-66).
  Beagle: Husky (D5-180) (J1-U).
O-360-A2D Piper Aircraft: Comanche (PA-24), Cherokee “C” (PA-28 “180”).
  Mooney Aircraft: Master “21” (M-20D), Mark “21” (M-20E).
O-360-A2E Std. Helicopter.
O-360-A2F Aero Commander: Lark (100).
  Cessna Aircraft: Cardinal.
O-360-A2G Beech Aircraft: Sport.
O-360-A3A C.A.A.R.P.S.A.N.: (M-23III).
  Societe Aeronautique Normande: Jodel (D-140C).
  Robin: Regent (DR400/180), Remorqueur (DR400/180R), R-3170.
  S.O.C.A.T.A.: Rallye 180GT, Sportavia Sportsman (RS-180).
  Norman Aeroplace Co.: NAC-1 Freelance.
  Nash Aircraft Ltd.: Petrel.
O-360-A3AD S.O.C.A.T.A.: TB-10.
  Robin: Aiglon (R-1180T).
O-360-A4A Piper Aircraft: Cherokee “D” (PA-28 “180”).
O-360-A4D Varga: Kachina.
O-360-A4G Beech Aircraft: Musketeer Custom III.
O-360-A4K Grumman American: Tiger.
  Beech Aircraft: Sundowner 180.
O-360-A4M Piper Aircraft: Archer II (PA-28 “18”).
  Valmet: PIK-23.
O-360-A4N Cessna Aircraft: 172 (Optional).
O-360-A4P Penn Yan: Super Cub Conversion.
O-360-A5AD C. Itoh and Co.: Fuji FA-200.
O-360-B2C Seabird Aviation: SB7L.
O-360-C1A Intermountain Mfg. Co.: Call Air (A-6).
O-360-C1E Bellanca Aircraft: Scout (8GCBC-CS).
O-360-C1F Maule: Star Rocket MX-7-180.
O-360-C1G Christen: Husky (A-1).
O-360-C2B Hughes Tool Co.: (269A).
O-360-C2D Hughes Tool Co.: (269A).
O-360-C2E Hughes Tool Co.: (YHO-2HU) Military.
  Bellanca Aircraft: Scout (8GCBC FP).
O-360-C4F Maule: MX-7-180A.
O-360-C4P Penn Yan: Super Cub Conversion.
O-360-F1A6 Cessna Aircraft: Cutlass RG.
O-360-J2A Robinson: R22.
IO-360-B1A Beech Aircraft: Travel-Air (B-95A).
  Doyn Aircraft: Doyn-Piper (PA-23 “200”).
IO-360-B1B Beech Aircraft: Travel-Air (B-95B).
  Doyn Aircraft: Doyn-Piper (PA-23 “200”).
  Fuji: (FA-200).
IO-360-B1D United Consultants: See-Bee.
IO-360-B1E Piper Aircraft: Arrow (PA-28 “180R”).
IO-360-B1F Utva: 75.
IO-360-B2E C.A.A.R.P. C.A.P. (10).
IO-360-B1F6 Great Lakes: Trainer.
IO-360-B1G6 American Blimp: Spector 42.
IO-360-B2F6 Great Lakes: Trainer.
LO-360-A1G6D Beech Aircraft: Duchess.
LO-360-A1H6 Piper Aircraft: Seminole (PA-44).
IO-360-E1A T.R. Smith Aircraft: Aerostar.
IO-360-L2A Cessna Aircraft: Skyhawk C-172.
IO-360-M1A Diamond Aircraft: DA-40.
IO-360-M1B Vans Aircraft: RV6, RV7, RV8.
  Lancair: 360.
AEIO-360-B1F F.F.A.: Bravo (200).
  Grob: G115/Sport-Acro.
AEIO-360-B1G6 Great Lakes.
AEIO-360-B2F Mundry: CAP-10.
AEIO-360-B4A Pitts: S-1S.
AEIO-360-H1A Bellanca Aircraft: Super Decathalon (8KCAB-180).
AEIO-360-H1B American Champion: Super Decathalon.
VO-360-A1A Brantly Hynes Helicopter: (B-2).
VO-360-A1B Brantly Hynes Helicopter: (B-2, B2-A). Military (YHO-3BR).
VO-360-B1A Brantly Hynes Helicopter: (B-2, B2-A).
( printed page 37961)
IVO-360-A1A Brantly Hynes Helicopter: (B2-B).
HO-360-B1A Hughes Tool Co.: (269A).
HO-360-B1B Hughes Tool Co.: (269A).
HO-360-C1A Schweizer: (300C).
HIO-360-B1A Hughes Tool Co.: Military (269-A-1), (TH-55A).
HIO-360-B1B Hughes Tool Co.: (269A).
HIO-360-G1A Schweizer: (CB).
O-540-A1A Rhein-Flugzeugbau: (RF-1).
O-540-A1A5 Piper Aircraft: Comanche (PA-24 “180”).
  Helio: Military (H-250).
  Yoeman Aviation: (YA-1).
O-540-A1B5 Piper Aircraft: Aztec (PA-23 “250”), Comanche (PA-24 “250”).
O-540-A1C5 Piper Aircraft: Comanche (PA-24 “250”).
O-540-A1D Found Bros.: (FBA-2C).
  Dornier: (DO-28-B1).
O-540-A1D5 Piper Aircraft: Aztec (PA-23 “250”), Comanche (PA-24 “250”), Military Aztec (U-11A).
  Dornier: (DO-28).
O-540-A2B Aero Commander: (500).
  Mid-States Mfg. Co.: Twin Courier (H-500), (U-5).
O-540-A3D5 Piper Aircraft: Navy Aztec (PA-23 “250”).
O-540-B1A5 Piper Aircraft: Apache (PA-23 “235”).
O-540-B1B5 Piper Aircraft: Comanche (PA-24 “250”).
  Doyn Aircraft: Doyn-Piper (PA-24 “250”).
O-540-B1D5 Wassmer: (WA-421).
O-540-B2B5 Piper Aircraft: Pawnee (PA-25 “235”), Cherokee (PA-28 “235”), Aztec (PA-23 “235”).
  Intermountain Mfg. Co.: Call Air (A-9).
  Rawdon Bros.: Rawdon (T-1).
  S.O.C.A.T.A.: Rallye 235CA.
O-540-B2C5 Piper Aircraft: Pawnee (PA-25 “235”).
O-540-B4B5 Piper Aircraft: Cherokee (PA-28 “235”).
  Embraer: Corioca (EMB-710).
  S.O.C.A.T.A.: Rallye 235GT, Rallye 235C.
  Maule: Star Rocket (MX-7-235), Super Rocket (M-6-235), Super Std. Rocket (M-7-235).
O-540-E4A5 Piper Aircraft: Comanche (PA-24 “260”).
  Aviamilano: Flamingo (F-250).
  Siai-Marchetti: (SF-260), (SF-208).
O-540-E4B5 Britten-Norman: (BN-2).
  Piper Aircraft: Cherokee Six (PA-32 “260”).
O-540-E4C5 Pilatus Britten-Norman: Islander (BN-2A-26), Islander (BN-2A-27), Islander II (BN-2B-26), Islander (BN-2A-21), Trislander (BN-2A-Mark III-2).
O-540-F1B5 Omega Aircraft: (BS-12D1).
  Robinson: (R-44).
O-540-G1A5 Piper Aircraft: Pawnee (PA-25 “260”).
O-540-H1B5D Aero Boero: 260.
O-540-H2A5 Embraer: Impanema “AG”.
  Gippsland: GA-200.
O-540-H2B5D Aero Boero: 260.
O-540-J1A5D Maule: Star Rocket (MX-7-235), Super Rocket (M-6-235), Super Std. Rocket (M-7-235).
O-540-J3A5 Robin: R-3000/235.
O-540-J3A5D Piper Aircraft: Dakota (PA-28-236).
O-540-J3C5D Cessna Aircraft: Skylane RG.
O-540-L3C5D Cessna Aircraft: TR-182, Turbo Skylane RG.
IO-540-C1B5 Piper Aircraft: Aztec B (PA-23 “250”), Comanche (PA-24 “250”).
IO-540-C1C5 Riley Aircraft: Turbo-Rocket.
IO-540-C4B5 Piper Aircraft: Aztec C (PA-23 “250”), Aztec F.
  Wassmer: (WA4-21).
  Avions Pierre Robin: (HR100/250).
  Bellanca Aircraft: Aries T-250.
  Aerofab: Renegade 250.
IO-540-C4D5 S.O.C.A.T.A.: TB-20.
IO-540-C4D5D S.O.C.A.T.A.: Trinidad TB-20.
IO-540-D4A5 Piper Aircraft: Comanche (PA-24 “260”).
  Siai-Marchetti: (SF-260).
IO-540-D4B5 Cerva: (CE-43 Guepard).
IO-540-J4A5 Piper Aircraft: Aztec (PA-23 “250”).
IO-540-R1A5 Piper Aircraft: Comanche (PA-24).
IO-540-T4A5D General Aviation: Model 114.
IO-540-T4B5 Commander: 114B.
IO-540-T4B5D Rockwell: 114.
IO-540-T4C5D Lake Aircraft: Seawolf.
IO-540-V4A5 Maule: MT-7-260, M-7-260.
  Aircraft Manufacturing Factory.
( printed page 37962)
IO-540-V4A5D Brooklands: Scoutmaster.
IO-540-W1A5 Maule: MX-7-235, MT-7-235, M7-235.
IO-540-W1A5D Maule: Star Rocket (MX-7-235), Super Rocket (M-6-235), Super Std. Rocket (M-7-235).
IO-540-W3A5D Schweizer: Power Glider.
AEIO-540-D4A5 Christen: Pitts (S-2S), (S-2B).
  Siai-Marchetti: SF-260.
  H.A.L.: HPT-32.
  Slingsby: Firefly T3A.
AEIO-540-D4B5 Moravan: Zlin-50L.
  H.A.L.: HPT-32.
AEIO-540-D4D5 Burkhart Grob: Grob G, 115T Aero.
TIO-540-C1A Piper Aircraft: Turbo Aztec (PA-23-250).
TIO-540-K1AD Piper Aircraft.
TIO-540-AA1AD Aerofab Inc.: Turbo Renegade (270).
TIO-540-AB1AD S.O.C.A.T.A.: Trinidad TC TB-21.
TIO-540-AB1BD Schweizer.
TIO-540-AF1A Mooney Aircraft: “TLS” M20M.
TIO-540-AG1A Commander Aircraft: 114TC.
TIO-540-AK1A Cessna Aircraft: Turbo Skylane T182T.
LTIO-540-K1AD Piper Aircraft.

Unsafe Condition

(e) This AD results from reports of 10 additional cylinder head separations since issuing AD 2008-19-05, on cylinder serial numbers not listed in that AD. We are issuing this AD to prevent loss of engine power due to cracks at the head-to-barrel interface in the cylinder assemblies and possible engine failure caused by separation of a cylinder head, which could result in loss of control of the aircraft.

Compliance

(f) You are responsible for having the actions required by this AD performed within the compliance times specified unless the actions have already been done.

Engines Overhauled or Cylinder Assemblies Replaced Since New

(g) If your engine was overhauled or had a cylinder assembly replaced since new, do the following:

(1) Before further flight, inspect the maintenance records and engine logbook to determine if the overhaul or repair facility used ECi cylinder assemblies, P/N AEL65102, with cylinder head, PN AEL85099, with a SN 1138-02 through SN 35171-22, or a SN 35239-01 through SN 42179-30, installed.

(2) If the cylinder assemblies are not ECi, P/N AEL65102, no further action is required.

(3) If the cylinder assemblies are ECi, P/N AEL65102, and if the SN is not listed in this AD, no further action is required.

(4) If the cylinder assemblies are ECi, P/N AEL65102, and if the SN is listed in this AD, do the following:

Group “A” Cylinder Assemblies

(i) For Group “A” cylinder assemblies:

(A) Perform an initial visual inspection as specified in paragraphs (h) through (i) of this AD, and an initial compression test as specified in paragraphs (j) through (n) of this AD, within the next 10 operating hours time-in-service (TIS), if the cylinder assembly has 350 or more operating hours TIS on the effective date of this AD, but fewer than 2,000 operating hours TIS.

(B) Perform an initial visual inspection as specified in paragraphs (h) through (i) of this AD, and an initial compression test as specified in paragraphs (j) through (n) of this AD, within the next 10 operating hours TIS, or before exceeding 350 operating hours TIS, whichever occurs later, if the cylinder assembly has fewer than 350 operating hours TIS on the effective date of this AD.

(C) Replace cylinder assemblies installed in helicopter engines within the next 25 operating hours TIS after the effective date of this AD if the cylinder assembly has 1,500 operating hours TIS or more on the effective date of this AD.

(D) Replace cylinder assemblies installed in airplane engines within the next 25 operating hours TIS after the effective date of this AD if the cylinder assembly has 2,000 operating hours TIS or more on the effective date of this AD.

(E) Perform repetitive visual inspections as specified in paragraphs (h) through (i) of this AD, and repetitive compression tests as specified in paragraphs (j) through (n) of this AD, within every 50 operating hours TIS.

(F) Replace cylinder assemblies installed in helicopter engines that pass the visual inspections and compression tests, no later than 1,500 operating hours TIS after the effective date of this AD.

(G) Replace cylinder assemblies installed in airplane engines that pass the visual inspections and compression tests, no later than 2,000 operating hours TIS after the effective date of this AD.

Group “B” Cylinder Assemblies

(ii) For Group “B” cylinder assemblies:

(A) Perform an initial visual inspection as specified in paragraphs (h) through (i) of this AD, and initial compression test as specified in paragraphs (j) through (n) of this AD, within the next 10 operating hours TIS.

(B) Replace the cylinder assembly within the next 25 operating hours TIS after the effective date of this AD if the cylinder assembly has 350 or more operating hours TIS on the effective date of this AD.

(C) Replace cylinder assemblies that pass the initial visual inspections and compression tests, before exceeding 350 operating hours TIS after the effective date of this AD.

Visual Inspection

(h) Visually inspect each cylinder head around the exhaust valve side for cracks or any signs of black or white residue of combustion leakage from cracks.

(i) Replace cracked cylinder assemblies before further flight.

Cylinder Assembly Compression Test

(j) Perform a standard cylinder differential compression test.

(k) During the compression test, if the cylinder pressure gauge reads below 70 pounds-per-square-inch, apply a water and soap solution to the side of the leaking cylinder, near the head-to-barrel interface.

(l) Replace the cylinder assembly before further flight if air leakage and bubbles are observed on the side of the cylinder assembly, near the head-to-barrel interface.

(m) Repair or replace the engine cylinder assembly before further flight if the cause of the low gauge reading in paragraph (l) of this AD is from leaking intake or exhaust valves, or from leaking piston rings.

Prohibition of ECi Cylinder Assemblies Affected by This AD

(n) After the effective date of this AD, do not install any ECi cylinder assembly, P/N AEL65102, with cylinder head, P/N AEL85099, and with SN 1138-02 through SN 35171-22, or SN 35239-01 through SN 42179-30, onto any engine, and do not attempt to repair or reuse these ECi cylinder assemblies.

Alternative Methods of Compliance

(o) The Manager, Special Certification Office, has the authority to approve alternative methods of compliance for this ( printed page 37963) AD if requested using the procedures found in 14 CFR 39.19.

Special Flight Permits

(p) Under 14 CFR part 39.23, we will not approve special flight permits for this AD for engines that have failed the visual inspection or the cylinder assembly compression test required by this AD.

Related Information

(q) Contact Peter W. Hakala, Aerospace Engineer, Special Certification Office, FAA, Rotorcraft Directorate, 2601 Meacham Blvd., Fort Worth, TX 76193; e-mail: ; telephone (817) 222-5145; fax (817) 222-5785, for more information about this AD.

Issued in Burlington, Massachusetts, on July 21, 2009.

Peter A. White,

Assistant Manager, Engine and Propeller Directorate, Aircraft Certification Service.

[FR Doc. E9-18118 Filed 7-29-09; 8:45 am]

BILLING CODE 4910-13-P

Published Document: E9-18118 (74 FR 37955)